FR2764234A1 - MULTILAYERED METAL SHEET SCREEN STRUCTURES AND MANUFACTURING METHOD - Google Patents

Abstract

Three-dimensional multi-layer metallic foil screen (1) formed by forging / stamping comprising areas where the layers are in a spaced relationship, areas where the layers are stretched or stretched and areas where the layers are compressed and locked with each other . The multilayer metal sheet screen (1) is formed by forging / stamping, in a suitable mold apparatus, a preform of a stack of layers of metal sheet between which spaces are provided. The spaces are produced by bosses (7) in the layers or by spacers between the layers. Multilayer metallic foil screens (1) are used as thermal screens and acoustic screens, particularly on vehicles. The three-dimensional screens (1) comprise structures formed from a sheet of multilayer sheet metal. Multilayer metal preforms with an intermediate flap or rolled edge are produced for transport to the final three-dimensional stamping operation.

Description

MULTI-LAYER METAL SHEET SCREEN STRUCTURES AND

MANUFACTURING PROCESS

FIELD OF THE INVENTION

  The present invention relates to multi-layer metallic foil screens used as screens

  thermal and as acoustic screens.

BACKGROUND OF THE INVENTION

  The multilayer metal foil insulation has been used for many years, as illustrated by U.S. Patent No. 1,934,174. This metal foil insulation has typically been used in high temperature applications for reflective thermal insulation. In these applications, the metal foil layers are embossed to ensure separation between the layers and the stack of layers is protected in a container or by a rigid cover to prevent the stack of metal sheets from being compressed into a any place, which would decrease the insulation value

of the battery.

  US Patent No. 5,011,743 discloses that this multi-layer metal foil insulation can provide improved performance as a heat shield when a portion of the multi-layer metal foil is compressed to provide a heat dissipation area through which the heat is collected from the insulation parts of the battery and dissipated from the heat shield. These multilayer metal foil heat shields are formed from a stack of embossed metal foil layers by compressing portions of the stack to create the desired heat dissipation areas. The layers are attached to each other or stapled to each other to prevent the layers from separating. Heat shields

  and the acoustic screens formed according to the description

  of U.S. Patent 5,011,743 are typically compressed in the heat dissipation areas and cut to a desired pattern. These multilayer metal sheet heat shields do not normally have sufficient structural strength for independent use in many applications. For many applications, metal foil heat shields are typically attached to a structural member or a support tray to provide a final assembly which is then put into service as a heat shield or acoustic shield. The support elements are typically metal trays or stamped blanks or castings of non-ferrous alloys. Typical applications for these heat shield assemblies include screen applications

automobile thermals.

SUMMARY OF THE INVENTION

  It is an object of the present invention to provide a multilayer metal sheet insulation structure which has sufficient structural strength to function as a heat shield or an independent unitary acoustic screen without the need to pre-assemble the metal sheet insulation.

  multilayer on a support element.

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  The multilayer metal sheet structures of the present invention include at least three layers of metal, at least two of which are layers of metal sheet 0.15 mm (0.006 inch) thick or less. It is generally preferable that the structures of the present invention contain at least three layers of metallic foil and, more preferably, typically contain five to seven layers of metallic foil. Preferably, the metal foil layers will be 0.005 inch (0.12 mm) or less, a metal foil of 0.002 inch (0.05 mm) being a preferred thickness for the inner layers in many screen applications. In addition to the metal foil layers, optional outer protective sheet metal layers on one side or both sides of the screen structure can be included. The sheet metal sheets have a thickness greater than 0.006 inch (0.15 mm) and up to about 0.050 inch (1.27 mm). The thickness of the optional protective outer sheet sheet is selected so that it can be formed and shaped as part of the unitary multilayer metal sheet screen structure according to the present invention. Preferably, the outer protective sheet sheet layers will be between about 0.008 inch (0.20 mm) and about 0.030 inch (0.76 mm). In the multilayer metal sheet structures of the present invention, one or more layers of such sheet metal sheets can be placed between the metal sheet layers, if desired, for additional structural strength of the metal sheet screen structure unitary multilayer

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  final. For some screen applications, the multilayer metal sheet structure may be made entirely of metal sheets having a thickness of 0.15 mm (0.006 inch) or less, without the use of any layer of thicker sheet metal. Multilayer metal sheet structures exhibit surprising structural strength and rigidity when formed by

  forging according to the present invention.

  The multilayer metal sheet structures according to the present invention are shaped by a forming process which includes providing a preform of at least three layers of sheet metal sheet, of which at least two layers are layers of metal sheet d '' a thickness of 0.15 mm (0.006 inch) or less, where the layers are spaced so as to provide spaces between the layers, the formation of the multilayer preform on a shaping mold, such that a first part of the preform is held in position to maintain the spaced positions to maintain the desired spaces between the layers, a second part of the preform is subjected to a tension stress to put the second part of the preform in the form of ribs or angles in order to form the desired three-dimensional shape and a third part of the preform is subjected to compression in order to put this third part of the preform in the form of a wall section positioned at an angle to the plane of the first part and an edge section in order to lock the layers with each other in this third part. The second part provides the transition between the first part comprising

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  spaced layers and the third part comprising compressed and mutually interlocked layers. The third part includes a wall section and an edge section. It is preferable that the layers are compressed and locked with each other both in the wall section and in the edge section. However, in certain configurations of the structures of the present invention, the layers can be compressed and shaped so as to form the wall section, but the layers are not interlocked with each other in part or throughout the section of wall. But, in these configurations, the layers are always compressed and locked with each other in the edge section where the layers are preferably folded, rolled or wrapped with each other at the edge to form a flap along from the edge of the structure. The compressed portion provides a three-dimensional shape to the structure and provides structural strength to the entire multilayer metal sheet structure by folding or folding the sheets of the preform into a interlocking relationship in the third portion to form a unitary rigid multilayer metal sheet structure. The forming operation, which simultaneously stretches the second part and compresses the third part of the multilayer metal sheet preform into the final multilayer metal sheet structure, gives three-dimensional rigidity and structural strength to the multilayer metal sheet structure final formed, while also maintaining the spaced layers and the spaces between the layers in the first part of the preform. The forming operation also locks the layers together in an edge portion of the structure, preferably by folding, rolling or winding the edge, forming, for example, a cylindrical flap along the edge of the

multilayer structure.

  The present invention provides a formed metal structure comprising at least three layers of sheet metal sheet, at least two layers of which are layers of metal sheet 0.15 mm (0.006 inch) thick or less, formed into a unitary structure three-dimensional, so that in one part of the structure, spaces are created between the layers by spacers so as to keep the layers separate and, in one part of the structure, the layers are locked and folded with each other to substantially eliminate the spaces between the layers, thereby providing three-dimensional structural strength of the final part. The multilayer metal sheet structure is formed three-dimensionally from a preform of a stack of said metal layers on a mold, such that parts of the layers are shaped under tension stress and parts of the layers are shaped under compression conditions to form the metal foil layers in folds, folds, or interlock rolls, while portions of the layers are held in a spaced relationship to spaces

between layers.

  The present invention provides multilayer metal sheet structures which are structures

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  independent, three-dimensional stable or rigid, which can be assembled or installed as independent products to be used as heat shields or acoustic screens, particularly in automotive applications, without the need for a tray, a stamped blank, a frame or other structural support element

for the screen.

  The present invention provides a method for forming a multilayer metallic structure by providing a multilayer preform of a stack of at least three layers of sheet metal sheet of which at least two layers are metallic sheets each having a thickness of 0.15 mm ( 0.006 inch) or less, where spaces are provided between the layers, and by forming said multilayer preform on a rigid mold, so that, in part of the preform, spaces are maintained between the layers, only in part of the preform, the layers are subjected to a tensile stress in order to put this part of the preform in the form of ribs or angles to form the desired three-dimensional shape, and that in part of the preform, the layers are subjected to compression to put part of the preform into a three-dimensional shape in order to give structural resistance to the metal structure by eliminating s silently the spaces between the layers and locking the layers with each other in this part of the preform in order to form a

  unitary structure in multilayer metal sheet.

  The present invention further provides the multilayer metallic structure formed and placed

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  shape as described above, in which the layers comprise three sheets of sheet metal each having a thickness greater than 0.15 mm (0.006 inch). Similarly, the present invention provides the method as described above for forming and shaping multilayer metal structures from a multilayer preform, in which the layers comprise three sheets of sheet metal each having a thickness greater than 0, 15 mm (0.006 inch). It is preferable, in these aspects of the present invention, that the preform and the resulting structure formed and formed comprise four to nine or more layers, while five to seven layers are preferable for many applications such as

thermal and acoustic screens.

  In a most preferred aspect of the present invention, screen pieces of multi-layer sheet metal sheet comprising three, four, five or more layers are formed from preforms of multi-layer sheet metal sheet by a single stamping operation which forms the multilayer preform into a shaped, rigid, three-dimensional structure, in which a part of the final part comprises the layers in a spaced relationship, a part of the part comprises at least part of the layers stretched or stretched around angles or ribs formed in the part and part of the part comprises the layers compressed vertically and longitudinally and / or laterally and locked with each other, preferably in a flap rolled, rolled up or folded along one or more edges of the part. Shaping and interlocking layers in a single stamping operation provides a method

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  very effective for making multi-layer metallic thermal and acoustic screens suitable for any desired end-use application. In another more preferred aspect, at least one, and preferably two, three or more layers of the stamped piece at one time is a sheet of sheet metal 0.15 mm (0.006 inch) thick or less , for example, 0.127 mm (0.005 inch), 0.0508 mm (0.002 inch) and 0.02032 mm (0.0008 inch). The single stamping operation can also include punching, in the part, attachment points or holes reinforced with bolts or screws to assemble the part on its location

  intended end use, such as on a vehicle.

  In another application of the preferred aspect below

  Above the invention, it may be desirable to first form the rolled, wound or folded flap along one or more edges of the multilayer metallic preform before subjecting the preform to the stamping operation. unique to form the final three-dimensional multi-layer metallic screen. In this application of the invention, the selected number of sheet metal sheets are stacked and cut to the desired studied screen shape, then stamped to form the rolled, rolled up or folded flap along the edges in order to form a preform for unitary multi-layer metal flap. The flap preform is substantially generally flat in shape, but includes areas in the shape where the layers are in spaced relationship and edge areas where the layers are rolled, wound or folded into a flap. To form this flat flap preform, the stack does not need to be cut before stamping. The initial stamping of the stack can cut in the

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  shape, the formation of edge reinforcement ribs and the punching, compression or formation of as many final or substantially final characteristics as desired in the final shaped screen, such as attachment points, openings for assembly with other parts in the final assembly, for example on a vehicle. The substantially flat (or other desired preliminary shape) multi-layer metallic preforms, with flap, are then efficiently transported (due to their minimum volume) to the final assembly location where they are then embossed in the form of a screen. structural, final three-dimensional desired for the final part studied. The final stamping operation can only achieve three-dimensional shaping by compressing certain areas, stretching or stretching certain areas, while maintaining the spaced relationship of the layers in a part of the part, or can also perform additional punching. , a cutting operation or another operation to form the desired final studied part. In another aspect of the present invention, fibrous materials, plastic, resin or other non-metallic materials are encapsulated between two or more layers of the multilayer sheet sheet structure. The non-metallic materials are preferably hermetically sealed in the structure by the rolled, rolled up or folded flap with the entire edge and all internal edges to hermetically seal the materials between the layers. Non-metallic materials can extend into the flap edge area and can be rolled, rolled up, or folded with sheet metal layers, or these materials can be cut to just stop

before the flap.

  Other characteristics and advantages of the invention will emerge more clearly on reading

  of the description below made with reference to

attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

  FIG. 1 is a perspective view of a screen made of a multilayer metallic sheet formed by forging

according to the present invention.

  Figure 2 is a partial section of the screen of

Figure 1.

  FIG. 3A is an illustration of a multilayer metallic sheet preform useful in the present invention. Figure 3B is a partial top view of the preform used to make the screen of Figure 1. Figure 4A is an illustration of the molds and the preform used in the process of forging sheet screen products multilayer metallic

the present invention.

  FIGS. 4B and 4C are sectional views of the screen product formed in the molds illustrated on the

Figure 4A.

  Figure 4D is a partial perspective view of a screen formed by the method illustrated in Figure 4A. FIGS. 5A, 5B and 5C illustrate a mold configuration and the operation for rolling the edge of a screen product to form a roll of the edge of the multilayer metal sheet on the screen product, for example in an operation stamping and

unique forming.

  FIG. 6 illustrates the application of a screen according to the present invention to a vehicle. Figures 7A, 7B and 7C illustrate the use of preforms with intermediate flaps according to the present invention.

DESCRIPTION OF THE INVENTION

  The present invention employs a metal shaping process to provide new multilayer metal sheet structures. Conventional methods for metal forming or stamping operations include compression shaping of a single metal element or a solid metal preform to provide a final metal article. According to the present invention, the preform consists of several layers of metal foil provided with spacers which provide spaces between the layers. Conventional metal shaping and forming, for example forging, is usually done with heat or a heated preform, but cold forming, forging or hot forging is also conventionally used on parts solid metal. The present invention provides methods similar to forging or forging which have been adapted and modified to provide methods as described herein for producing the formed multilayer metal sheet structures of the present invention. Heating or a heated preform can be used, but is not necessary in the process of the present invention, which is preferably carried out at room temperature. The method used to form the multilayer metal sheet structures presented herein includes suitable methods similar to stamping, hydroforming and the like. In the methods of the present invention, a multilayer metallic sheet preform in which spaces are provided between the layers is subjected to a forming or stamping operation somewhat similar to forging or cold stamping in order to provide a structure rigid resulting metal which is a multilayer metal sheet structure formed into a three-dimensional part, in which the final structure comprises three distinct parts. In a first part of the structure, the layers of the preform were placed under tension stress conditions during the shaping operation to flatten or stretch this part of the layers of metal foil, for example around the corners, ribs or protrusions in the final piece. Another second part of the structure was placed under compression conditions and subjected to compression forces during the shaping operation in order to form this part of the layers of metal foil in folds, rolls, folds, in windings, or in another configuration which locks the layers together and gives the layers a desired degree of stiffness and a desired three-dimensional structural strength. In this second part

  of the structure, the compression is vertical, that is

  say normal to the plane of the layers, as well as longitudinal and / or lateral, substantially along the plane of the layers in order to fold, fold, or otherwise lock the layers with one another in a unitary rigid structure. In this second part of the structure, it is also preferable to roll, fold, roll up or otherwise lock the metal layers together.

  with others, preferably at the edge of the room.

  In another third part of the structure, the layers are neither stretched nor compressed significantly, so that the spaces between the layers of metal foil are substantially maintained. So an art specialist following the

  present description will realize that the molds

  used to form and shape the multi-layer metal sheet preform can be manufactured so that, when the part is formed, a first part of the multi-layer metal sheet preform is stretched or stretched, a second part of the metal sheet preform multilayer is formed by compressing the metal foil layers with each other, so that the layers are locked with each other by folding, winding, folding, winding, winding, folding, etc. ., and a third part of the preform in multilayer metal sheet remains substantially neutral, that is to say that the third part is neither stretched nor compressed, o the pre-existing spaces between the layers in the preform remain between the layers of metallic foil in the final formed part. In the second part, compression preferably includes longitudinal compression to fold, fold or otherwise lock the layers together.

others in a unitary structure.

  The spaces between the layers of metal foil are produced by spacers which maintain the layers in a desired spaced relationship in order to form the desired spaces and distance between the layers, depending on the properties of thermal and / or acoustic screen. desired in the final shaped and formed multi-layer metal screen. The spacers may be in the form of bosses, corrugations, or other deformations in at least one of the layers of metal foil, including bosses, folds, folds, and the like. These deformations are preferred because they can be easily reduced, stretched, flattened, etc., during the forming and shaping operation of the part of the present invention, deformations which facilitate the forming and shaping of the preform in a multilayer metallic sheet

  in rigid unitary structure of the present invention.

  In addition, the spacers providing the spaces between the layers can be metallic or other spacers or materials, such as pieces of metallic foil or metallic foil mesh, which can be compressed as desired in areas where the layers must be compressed and locked with each other, or the spacers may be parts, spheres, bars, etc. non-compressible in areas where it is desirable to have spaces between

layers.

  During the multilayer metal forming and shaping process according to the present invention, the multilayer metal sheet preform is compressed on a mold or is compressed between two substantially rigid forging molds in order to put the multilayer metal sheet preform in the shape of the desired final locked structure and in three-dimensional shape. The forming and shaping operations of the present invention are intended to include shaping and hot or cold forming of the preform into a multilayer metallic sheet. In the forming operation, part of the preform will be subjected to tensile stress or stretching which can range from mild tensile stress to somewhat extreme tensile stress. The tension stress usually occurs at the angles, at the elbows or other contours or forms of the structure, particularly the convex forms, where the layers pass from one plane or contour to another. Under light tension stress in these regions, one or more of the metal foil layers, which have been pre-embossed, corrugated, folded, or otherwise deformed or shaped to provide spaces between the layers, can be flattened or stretched in a smooth state, so that all or part of any bumps, undulations, bumps or folds, originally present in the multilayer metal sheet preform in this area, can be partially or completely smoothed under stress conditions tension or stretching present in this particular area of the preform when the preform is subjected to the shaping and molding operation. Under conditions of extreme tensile stress or stretching resulting from a particular configuration of a formed or molded multilayer metal sheet part, one or more of the metal sheet layers may, in reality, be subjected to elongation in order to facilitate the formation of the desired final three-dimensional multilayer metal sheet structure. Care should be taken to select and design the preform layers and the shaping / shaping / molding for a particular desired structure so as to avoid excessive tearing or breaking of any of the sheet layers metallic in the part

  subjected to tension stress or stretching.

  For example, in the extreme contour of the parts, it may be necessary for the preform to contain layers of metal foil having hyper-heavy deformations, such as ripples, bosses or folds, in order to allow the part to be shaped by the 'elongation or flattening of these deformations in the mold without tearing or breaking the sheet layer in the stretched parts of the shaped part. Although slight tearing of the inner layers of the sheet metal sheet stack may be tolerated for certain screen applications of the sheet metal structures of the present invention, it is preferable not to have discontinuous layers, particularly for the layers external. The shaping or molding of the preform into a multilayer metal sheet can be carried out by pressing the preform between two rigid molds, by pulling or pushing the preform on a punch

  single, or pushing the preform in half

  single shell. Shaping or forming on or in a single mold can be carried out by tightening the edges of the preform and by pulling, or by pressing with an elastic element, such as a rubber shape of suitable hardness and shape. The appropriate mold shape and material can be selected by an expert in the art according to the

  description to allow, as appropriate, to

  the preform to conform to the desired mold and form the folds or folds in the selected wall portions of the final piece formed by forging, thereby providing structural strength

  desired three-dimensional shape of the final shaped part.

  Likewise, the interlocking of the layers of metal foil can be done by folding, folding, rolling, winding or winding the layers together in order to achieve the

  desired unitary three-dimensional structure formed.

  For example, for some parts, it may be desirable to fold, roll or compression wrap the edges, or at least one edge, of the multilayer metallic sheet preform into a cylindrical or otherwise shaped roll or flap to lock the layers together before forming the part. This folding or winding of the layers in a cylindrical or flap shape can be carried out at an area or part of an interval of the part to lock the layers with each other, that is to say that it does not necessarily have to be made at an edge of the finished part. For other parts, it will be desirable to form the part first, cut the burrs or waste at the edges, then fold or roll the edges of the shaped multilayer preform in order to finish the interlocking of the layers. for structural strength. When forming certain pieces of multilayer metal sheet, it will be desirable to fold or fold a central or interior part of the multilayer preform to achieve both the desired shape and the desired interlocking of the layers for the three-dimensional structural strength of the room. In such a part, the edges can also be folded, wound or wound up, for example in a cylindrical roll, in order to provide additional structural strength, or one or more edges can be left uncompressed as part of the part of the structure where the spaces between the layers of metal foil are maintained. In some rooms, it may be desirable to provide a wire or other element around which the metal layers are folded, wound or wound into a cylindrical shape. The wire or other reinforcing element can provide additional structural strength or rigidity to the finished part or can be integrated with attachment points in order to mount the part, for example, on a

vehicle.

  As will be evident from the teachings of this document, it will often be desirable for the space between certain areas of the rigid two-part forming molds, when closed, to form a mold cavity having an approximately equal opening to the initial total thickness of the multilayer metal sheet preform, such that, during the forming and shaping operation, the layers of metal sheet in these areas of the preform are neither subjected to stress tension, nor compressed. These areas simply remain at the thickness or dimensions of the original preform and the spaced layers, thereby maintaining the original spaces between the layers. It will be appreciated that it is the zones, together with other parts or zones of the preform, which are not subjected to significant or total compression, which provide a large part of the thermal and acoustic insulation properties of the structures in multilayer metal sheet formed according to the present invention. And, the areas in which the metal foil layers are formed, stretched, compressed and / or locked with each other are the areas which provide much of the structural strength of the metal foil screen

multilayer shaped and formed.

  In the part of the preform which is subjected to compression to form the locking of the multiple layers and to form the unitary multilayer metallic sheet structure proposed by the present invention, the compression in the appropriate parts of the preform is studied to result in the locking multiple layers of metal foil with each other by folding, folding, rolling, winding or winding the layers to form, for example, a cylindrical roll preferably at an edge of the structure. The compression of the layers of metal foil to form the locked layers, particularly by folding (which consists of the frequent repetition of small folds of the layers in a regular or irregular pattern), the compression of the multilayer preform is preferably done in the longitudinal and / or transverse direction as well as in the vertical direction where the vertical direction is normal (direction z) to the plane of the layers and the longitudinal or transverse direction is along the plane of the layers (direction x or y). Vertical compression of the layers tends to reduce or eliminate the spaces between the layers. Longitudinal or transverse compression of the layers ensures the gathering or folding of the excess sheet metal material or covering which can fold or fold the layers with each other, thus allowing the interlocking of the layers when the final compression including vertical compression, of these parts of the structure, is accomplished. In these locked parts of the structure, the spacers providing the spaces between the layers will be at least partially, if not completely, eliminated or compressed, so that there will be essentially no space between them in these locked parts and compressed from the final screen piece. Although these parts of the structure may exhibit reduced thermal and acoustic insulation performance, it is these parts of the multilayer metal sheet structure which give the unitary structural resistance to the final multilayer metal structure formed. Following the method and teaching of the present invention, these unitary multi-layer metal sheet structures comprising layers of metal sheet 0.15 mm (0.006 inch) thick or less are easily designed with or without one or more

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  protective external metal layers or sheets which are thicker than 0.18 mm (0.007 inch) and can be designed as a whole screen piece with mounting hardware or fixing mechanisms. The shaped and formed multilayer metal sheet structures of the present invention can, therefore, be used directly in the desired application, for example as an automobile thermal or acoustic screen, without the need for a blank die-cut part. , a bin or a

support frame member.

  As will be further evident from the teachings of this document, the multi-layer metallic preform will, first, be formed into a pre-flap preform which is substantially flat or of another shape desired for efficient transport to a forging or shaping operation to produce the final three-dimensional metallic multilayer studied part. In this application of the invention, the selected number of sheet metal sheets are stacked and cut to the desired studied screen shape, then stamped to form the rolled, rolled up or folded flap along the edges in order to form a preform for unitary multi-layer metal flap. The flap preform is substantially generally flat in shape, but includes areas in the shape where the layers are in spaced relationship and edge areas where the layers are rolled, wound or folded into a flap. For the formation of this flat flap preform, the stack does not need to be cut before stamping. The initial stamping of the stack can perform the cutting in the shape, the formation of the edge reinforcement ribs and the punching, the

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  compression or formation of as many final or practically final characteristics as desired in the final shaped screen, such as attachment points, openings for assembly with other parts in the final assembly, by example on a vehicle. The substantially flat (or other desired preliminary shape) multi-layer metallic preforms, with flap, are then efficiently transported (due to their minimum volume) to the final assembly location where they are then embossed in the form of a screen. structural, final three-dimensional desired for the final part studied. The final stamping operation can only achieve three-dimensional shaping by compressing certain areas, stretching or stretching certain areas, while maintaining the spaced relationship of the layers in a part of the part, or can also perform punching. additional, a cutting operation or another operation to form the desired final studied part. The usefulness of the multilayer metal sheet structures formed by forging of the present invention includes heat shields and acoustic shields in various applications. For example, the independent unitary multilayer metal sheet structure of the present invention is particularly suitable for forming specialized heat shields for automotive use, such as heat shields mounted on automobile engines, heat shields for electronic components under hood, transmission heat shields and the like, where protection is provided against heat from the exhaust system. Consequently, the thermal screens formed according to the present invention are lighter, more easily recycled and, depending on the particular design and the end use application, often more effective as thermal screens than conventional thermal screens, which are typically a single layer metal screen or a sandwich construction comprising a conventional insulation material, such as rock wool. The unitary, rigid and independent multilayer metal sheet screen structures of the present invention can directly replace these conventional screens. Although the thermal or acoustic performance of the multilayer metal sheet structure screens of the present invention can be improved to some extent by filling the spaces between the metal layers with various insulation materials, this is generally not preferred because very effective insulation properties of the multilayer metal sheet screens of the present invention without these filling materials and because of the increased manufacturing cost and the difficulty of recycling these parts filled with insulation. However, in some screen applications, various additional materials may be desired between certain layers or on the surface of various layers of metal foil. For example, in certain acoustic screen applications, a film or a layer of plastic can be used between the layers of metal foil, either over the entire area of the screen, or only in certain parts, for example the areas where spaces remain between the layers once the screen has been shaped and formed. Another example is the use of a sheet or layered adhesive or a layer of sprayed adhesive between the layers of metallic foil or on one or both sides of one or more layers of metallic foil. In the application of an acoustic screen, these intermediate layers will have the advantage of damping sounds and vibrations by avoiding a point of metallic contact between the layers of metal foil and by adding a mass to absorb the vibrations. This will be particularly advantageous in screens having large, substantially flat areas. The selection of the materials desired to improve the acoustic screen properties of the multilayer metal foil screens of the present invention will be obvious to a person skilled in the art, recognizing that the materials useful for improving the acoustic screen performance may not be appropriate for them

heat shield applications.

  Other materials which may be used between the metal layers include fiber materials in the form of wafers, mats, woven, non-woven fibers, fabrics, overlay

  prepreg layers, or blown free fibers.

  The fibers may be of the inorganic type, for example glass fiber, rock wool or ceramic, or may be of the organic type, for example polyester, aramid, cellulose (for example paper), cotton, wool, grain / silk stalk, linen, DAF, sisal and the like. The material may be a foam (with open or closed cells) in layers or in pieces, a gel in layers or in pieces or an elastomer. All of these materials can be mixed or layered with each other or with a thin sheet of metal or plastic, for example 0.8 thousandths of an inch, in a smooth, perforated, hard or any form of texture. what other desired shape, including wavy, bumpy, expanded mesh, and the like. These materials can be found only inside the structure or can be incorporated in the rolled, rolled or folded edge part of the structure. Part of the material present in the edge part can be melted, decomposed, thermoset, activated by the application of heat to the edge part. Likewise, these materials can be treated, hardened or conditioned to heat by applying appropriate heat to the interior of the

  structure in addition to or in place of the edge part.

  These materials used in proper combination with the sheet metal sheet and the metal sheet layers can result in the design of any desired thermal, acoustic, structural, environmental, shutdown and other properties. Another unique use of the shaped and formed multilayer metal sheet screen structures of the present invention is a direct application of these screens to underbody areas of an automobile as a thermal and acoustic screen, particularly by direct attachment to the exterior surface of passenger compartment floor of automobiles. For example, the multilayer metal sheet structures of the present invention can be precisely formed and shaped so as to fit exactly and uniformly on the desired surface portions of the exterior of the floor of the passenger compartment of an automobile . These screen structures of the present invention may be attached to the exterior surface of the floor by conventional fasteners but, preferably, by a contact adhesive or a mastic material applied uniformly to the surface or by

  points across the surface of the screen and the floor.

  The multilayer screen structures of the present invention can be formed to fit and exactly match the entire floor of the passenger compartment of the automobile and can be made in any size, so as to cover n ' any desired part of the floor surface. Alternatively, the screens of the present invention can be shaped and formed in sections, then attached, by desired means, to the selected parts or areas of the floor of the automobile. In either method, the multilayer metal screen structures of the present invention provide lightweight, recyclable products which can be used economically as a thermal or acoustic screen for all purposes.

  passenger compartment floor of the automobile.

  Likewise, the shaped and formed multilayer metal sheet screen structures of the present invention can be manufactured to be placed on the engine side of a firewall of an automobile, thereby achieving a insulation and a thermal and acoustic screen for the passenger compartment of the automobile on an integrated basis. The multilayer metal sheet structures of the present invention produce light and recyclable products which can economically achieve this thermal and acoustic screen on large surfaces, while being strong enough to be fixed directly to the desired automotive component. , without the need for a bin or

a separate support frame.

  The materials used in the multilayer metal sheet structures of the present invention will, of course, depend on the particular use.

  and required performance properties of the product.

  Typically, aluminum foil will be used for most insulation or thermal and acoustic shield applications, particularly for automotive underbody applications and moderate temperature heat shields, such as mounted screens. on the engine and heat shields in other engine compartments or under the hood. In particular, the heat shields according to the present invention are useful for protecting the electronic and computer components in the engine compartment from the heat of the engine and of the exhaust system. In other applications, such as the exhaust manifold or downstream exhaust pipe screen applications, another material, such as stainless steel sheets, will be required in order to withstand the ambient temperature and meet sustainability requirements. The selection of particular metal sheets for a particular application will be obvious to a specialist in the art taking into account ambient noise and vibrations, as well as the properties of sheet metal sheets and metal sheets necessary in order to shape and form effectively sheet screen structures

  multilayer metal according to the present invention.

  The present invention is further illustrated by reference to the drawings. Figure 1 is a perspective illustration of an example of a typical multi-layer metallic foil screen of the present invention formed by the method of the present invention. The heat shield (1) illustrated in Figure 1 consists of five layers of aluminum sheet where the top layer is 0.254 mm (0.010 inch) thick, the three inner layers are sheets each having a thickness of 0.0508 mm (0.002 inch) and the bottom layer is aluminum foil having a thickness of 0.127 mm (0.005 inch). The part is formed from a flat preform, as referenced above and as illustrated below in Figure 3B, where the preform is a stack consisting of the layer of aluminum sheet and the four layers aluminum foil which have been embossed with bosses (7) in order to create the spaces between the layers. During the formation of the screen (1) from the preform, the aluminum sheets are stretched by being subjected to a tensile force in the corner area (2) as well as compressed in order to form the area of angle (2) extending around the area (6). During the forming operation, the aluminum sheets are compressed with each other to form the wall section (4) in which the aluminum sheets are compressed longitudinally (x and / or y) as well as vertically (z ), so that the layers of aluminum foil are gathered and folded

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  with each other and folded on top of each other, then compressed, so that the five layers are locked together with pleating and folding in order to form a rigid wall (4) having the folds and the ribs (8) shown in Figure 1. The edges of the metal foil layers are then rolled and wound up to form an edge roll (5) along the bottom edge of the wall portion (4) of the screen. Mounting brackets (9) are spot welded in the wall section (4), see for example US Patent 5,524,406 to Ragland, which mounting brackets can be used to bolt the screen to a vehicle for which the piece is designed. Attachment points (9) are preferably placed in the wall section (4), but they can be placed in any part of the screen, including areas (2) and (6). A cut-out area (10) is typical of an auto part that must be designed to fit around other contiguous components where the screen is

installed on the automobile.

  As can be seen in Figure 1, the area (6) of the screen has not been stretched or compressed and remains substantially in its original preform shape, so that the bosses (7) separate the layers and create spaces between them. This can be seen more clearly in Figure 2, which is a

  partial section view 2-2 of the screen of FIG. 1.

  With reference to FIG. 2, the partial section illustrates the layers of metallic foil (21) comprising the bosses (7) separating the layers of metallic foil in the area (6). In the area (2)

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  of the screen, the metal foil layers were stretched and stretched during the forming operation, thereby smoothing and substantially eliminating the bumps in the area (2) by tension and stretching as well as by compression during the forming and shaping operation. In the wall section (4), the metal sheets are folded and folded with each other, so that the folds and folds, when compressed on top of each other, lock at least a part and, preferably, all the layers of metallic foil with each other thus achieving a resistant multilayered locked wall which gives astonishing structural resistance to the screen structure. In addition, the edge portion of the compressed and locked area of the metal foil layers is then rolled and formed to create the edge roller (5) which further locks the metal foil layers and provides more structural strength and integrity

rigid dimensional on screen.

  It will be obvious to a specialist in the art, that the screen (1) of FIGS. 1 and 2 is intended to be used as an independent structural automobile part, which can be mounted directly on an automobile without the need for a tray or support frame member. Although the top cover layer of the screen (1) is 0.254 mm (0.010 inch) aluminum sheet and the remaining layers are 0.0508 mm (0.002 inch) aluminum foil layers and 0.127 mm (0.005 inch), the five-layer aluminum sheet structure is very strong and able to withstand, even by direct mounting, the structural requirements and vibration loads it must

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  suffer in automobile use. It will also be obvious to a specialist in the art that the figures illustrating the present invention are only an example of an infinite number of three-dimensional shapes of sheet metal and multilayer metal sheet screens which can be designed and formed. from a multilayer preform. The spaced area (6), the stretched or stretched area (2), the wall section (4) and the edge portion (5) can be designed and formed into any structural shape desired for any application screen, including, for example, a plurality of each part or area, even in a repetition of units of each area, with

  fixing points (9) positioned as required.

  For example, it is not necessary that the entire edge portion is compressed and formed into a roll, some portions of the edge portions of a particular screen structure may be the edge of the area (6) where the layers of spaced metal foil are not compressed, spaces between the

layers at the edge of the screen.

  Figure 3A illustrates in diagram form a preform of embossed metal foil layers positioned in a preform stack for use in the process of the present invention to form the three-dimensional shaped products according to the present invention. The preform (30a) comprises layers (31) of metal foil having bosses (7) which separate the layers and the spaces between the layers. As referenced here, compression in the vertical direction (z) is called compression in the direction normal to

  plane of the surface of the layers of metallic foil.

  The transverse or lateral direction (x) and the longitudinal direction (y) refer to the directions along the planes of the layers of metal foil. It will be understood that this vertical direction, this transverse direction and this longitudinal direction, to which reference is made here, vary and follow the plane and the surface of the layer of the preform while it is deformed and shaped into three-dimensional shapes. It will also be understood that, instead of bosses in a preform, the layers of metal foil can be folded, corrugated, or otherwise treated, deformed or surface treated in order to provide flexibility and elongation potential, as well as compressibility, preferred for better use in shaping and forming the preform into a multilayer metal sheet according to the present invention. It is also understood that some of the layers of metal foil can be bumpy, folded or corrugated and that other layers can be smooth, while still other layers can be separated by other spacers such as pieces of sheet. , a leaf trellis and the like. The selection of the particular method for forming the individual layers for use in the preform and for forming the spaces between the layers will be obvious to those skilled in the art applying the invention described herein. In some cases, spaces between layers may be due to the folds that inherently occur in sheet layers

  metallic during handling and processing.

  FIG. 3B is a top view illustrating a part of the preform (30b) which includes the stack of aluminum sheets and the upper layer used to form the screen (1) shown in FIG. 1. By visualizing this preform, it will be obvious to a specialist in the art that the zone or the part (6) of the preform results in the zone (6) of the screen (1) in FIG. 1, while the zones (2), ( 4) and (5) of the preform also result in the forms (2), (4) and (5), respectively, and form these, in the screen of FIG. 1. For the purposes of illustration, these zones are delimited, in the representation of the preform (30b) of FIG. 3B, by dotted lines, which dotted lines have no other meaning than to show which zones of the preform are shaped in the corresponding areas of the formed screen (1) of Figure 1. By comparing the preform of Figure 3B to the final formed screen (1) of Figure 1, we can see that the area (2) is subjected to a lateral or longitudinal tensile force and stretched and also subjected, to a certain extent, to vertical compression in order to form the corner area (2) of the screen (1 ). In another aspect, taking into account the preform compared to the final formed screen, it is obvious that the zones (4) and (5) of the preform must be compressed in the longitudinal direction (y) by pleating, by folding, or otherwise, in order to collect excess metal foil material from the large perimeter area (4) and (5) of the preform (30b) of Figure 3B to result in the smaller or shorter perimeter area of the wall (4) and the roller (5) of the final formed screen (1) of Figure 1 leading, once the wall area (4) is formed, in three-dimensional shape. It is this longitudinal compression in the longitudinal direction (y) during the forming and shaping operation which results in the folds and the locking folds (8) shown on the wall section (4) of FIG. 1. The preform shown in Figure 3B also illustrates how the preform can be cut to contain the attachment points (9) and the cut (10) which then appears in the screen (1) of the final formed product shown

in figure 1.

  The preform selected to form and shape a particular screen or part can be a flat stack of sheet metal sheets, which is then fully formed and cut to size in a preferred single stamping / forming operation, such as described above. Alternatively, the preform can be cut or cut to size before forming or stamping. Likewise, the preform can be assembled from individually or partially formed sheets which are nested in a partially formed preform, then finished to form the multilayer metallic structures of the present invention. Another example is that the flat stack of metal sheets and sheet metal sheets is cut, then partially formed in a first forming operation, for example forming the roll edge, then finished in a second forming operation or stamping to produce the final multilayer metal sheet structure. In the single-stamping / forming embodiment of the present invention, the method is easily adapted to a continuous supply of sheet metal sheets and pre-prepared metal sheets, for example embossed, in multiple layers in a stamping operation. stamping o the three-dimensional structural parts of finished multilayer metal sheet are cut and formed from the continuously fed multilayer preform. Such a continuous supply of the preform can also be used in the forming and stamping of parts where two or more forming steps are carried out for

produce a finished part.

  FIGS. 4A to 4D illustrate the process of the present invention for the forming and shaping of preforms in a multilayer metallic sheet in three-dimensional unitary screen structures. FIG. 4A illustrates the punch and the half-shell (46) and (44) which are used to form the preform in a multilayer metal sheet (40) which comprises layers of embossed metal sheet (41). When the molds (44) and (46) close on the preform (40), the cavity which remains between the surfaces (6F) and (6M) when the mold is closed results in the area (6) of the screen ( 42) illustrated in Figure 4B. In area (6), the embossed metal foil layers remain uncompressed and have spaces between the layers. In the mold of FIG. 4A, when the surfaces (2F) and (2M) are paired, they form by stamping the preform in a multilayer metallic sheet (40), so that in the zones (2) of the screen (42 ) shown in Figure 4B, the metal foil layers are stretched and smoothed under the longitudinal tensile force and compressed vertically to form the shoulder area (2) of the screen (42). Similarly, when the surface areas (4F) and (4M) in the mold illustrated in FIG. 4A are paired by closing the mold, they compress and form the wall section (4) of the screen (42) of Figure 4B by folding and locking the layers of metal foil with each other in the wall area (4). The remaining parts of the molds (44), (46) of Figure 4A compress and form the parts of

  edge (43) of the screen (42) illustrated in FIG. 4B.

  The edge portions (43) are then folded and compressed to form the rigid edge flanges (45) illustrated in Figure 4C. Although the illustration in Figure 4C shows a rigid folded edge rim portion which can be compressed to form a rigid folded edge portion, it is recognized that in many cases it will be preferable to form a rolled or rolled cylindrical edge , as illustrated in FIGS. 1 and 2. Other forms of folding, winding, rolling, etc., from the edge to form the appropriate structural strength along the edge will be obvious to those skilled in the art from the teachings of the present invention. It should also be noted that in zones (2) and (4) of the screen formed by forging (42) of FIG. 4B, the original bosses, undulations or deformations present in the preform in these zones are essentially stretched, smoothed, destroyed, flattened or deformed by the forming operation, so that the spaces between the layers of metal foil are essentially eliminated, particularly in area (4). In area (2), there may be some space between the layers, depending on the lateral stretch and vertical compression applied during the forming and shaping operation. The layers in zone (2) can be partially spaced, largely smooth layers, where the bosses, undulations, etc.,

  have been pressed or stretched so that they are smooth.

  In area (4), the spaces between the layers will be almost completely replaced by small pockets or cavities, if there are any, since the layers are crushed and folded with each other and then compressed in order to lock the layers the

with each other.

  Figure 4D is a partial perspective view of the heat shield (42) illustrated in Figure 4C in which the area (6) contains the remaining bosses which separate the layers of metal foil (41) in the area (6). The area (2) is the corner area where the layers of metal foil have been stretched and stretched to form the corner area (2), and the wall area (4) has the folds and folds o the layers of metal foil (4) are pressed and locked with each other to form the structural wall area (4). Folding, clamping or winding the edge to form the edge roll (45) provides additional structural rigidity to the formed screen. If desired, the edge roll (45) can be spot welded at various locations to provide additional rigidity to the structure and to prevent any tendency of the edge to unwind during installation or use. The screen (41) illustrated in Figure 4D is an example of a type of multi-layer metallic sheet screen structure formed by forging of the present invention which can be used on automobile or vehicle exhaust systems below the vehicle to protect the compartment

  heat exhaust system passengers.

  Figs. 5A, 5B and 5C are illustrations of a preferred mold and forming and shaping method for forming a rolled edge on the multilayer metal sheet structure of the present invention by rolling the edge using a suitable suitable part of the forming mold. FIG. 5A is an illustration of the edge part of the forming mold where the wall part (4) of a screen structure as illustrated in FIG. 2 has been formed between the punch and the half-shell of forging (54M) and (54F), respectively. As illustrated in FIG. 5A, the mold comprises independently movable peripheral parts (52) and (53) and additional independently movable parts (57) and (58). When the molds close initially, all the mold parts (54F), (52) and (57) act in unison, as do the mold parts (54M), (53) and (58). Once all mold parts are closed, the wall section (4) is formed and the edge sections (55A) and (55B) are formed, then the mold parts (57) and (58) are separated. , separately, mold parts (52) and (53) for detaching from the edge of the stack of multilayer metal sheets the section (55B) which becomes waste. This cuts the edge portion (55A) to the desired length and allows the mold portions (52) and (53) to move downward in order to bend the remaining edge portion (55A) to a down position in the space formed by the spacing between the mold part (52) and the mold parts (54F)

  and (54M), as illustrated in Figure 5B.

  The winding of the edge part (55A) to form the edge roller (55) is then carried out, as illustrated in FIG. 5C, by closing the mold parts (52) and (53) one with the other, then moving the mold parts (52) and (53) in an upward movement. The formed cavity (59) directs the edge portion (55A) in a winding or circular motion to form the edge in a cylindrical roller (55) as the mold portions (52) and (53) move toward the top, stopping at the appropriate place so that the formed edge roller (55) is correctly positioned at the bottom of the wall (4). The mold is then separated in order to release the finished part and the piece of waste. Figures 5D, 5E and 5F illustrate that the edge roller (55) can finally be formed and positioned relative to the wall portion (4) so that the edge roller (55) is above, at - below or online, respectively, with

the wall part (4).

  In the molding and shaping process of the present invention, a preferred aspect is to use a protective layer between the mold and the multi-layer sheet sheet preform. The layer can be a layer of evaporation oil, a mold lubricant or a layer of polymer, such as polyethylene, which can remain on the formed part until it is installed, or which can be removed and reused or discarded immediately upon removal of the part from the mold. Likewise, intermediate layers can be used between the sheet metal sheet and metal sheet layers to aid formability during shaping and molding of the sheet metal / multi-layer metal sheet preform by helping the layers to slide or to shift relative to each other. In one embodiment, a vaporized or layered adhesive material can be used for this purpose, then, once the part is formed, the part is cured at a temperature to cure the adhesive and fix the layers together with others at most, if not all, points of contact. Such an adhesive reinforced part can provide additional structural strength for independent applications and can provide

  additional acoustic screen performance.

  Figure 6 is a schematic illustration of the application of a screen (42) illustrated in Figure 4D, to the underbody section of a vehicle (60). The screen (42) can be applied to the bottom surface of the tank or the floor (61) of the passenger compartment by mechanical fixing or by gluing. It should also be understood that a screen, such as the screen (42) of Figure 4D as well as any desired form of multi-layer metallic foil screen, can be designed and formed or shaped in accordance with the present invention so as to suit any desired part of the underbody of a vehicle, or of the firewall or other area of the engine compartment, etc., of a vehicle. The screens produced according to the present invention are advantageously fixed to the parts of the vehicle by gluing or by another mechanical fixing in order to produce an integral part of the bodywork or chassis. Because the efficient, lightweight, recyclable screens of the present invention can be designed to precisely suit any part of the vehicle, these screens provide a desired combination of heat shield and acoustic shield at any location. desired vehicle. It should also be recognized that direct attachment by mechanical attachment or by bonding of the multilayer metal foil screens of the present invention to the desired areas and components of a vehicle is permitted and made possible by the inherent structural strength of the screens and the parts thereof. multilayer metal sheet formed according

  the teaching of the present invention.

  Figure 7 is a schematic illustration of another aspect of the present invention as described above, in which the flap preform is made as an intermediate product, transported to a final forming and shaping operation and formed into the desired final studied piece. In this application of the invention, FIG. 7A illustrates a multilayer preform (40) comprising separate metal layers (71), which preform (40) can be uncut (see FIG. 3A) or can be cut into a desired shape (see Figure 3B). The preform (40) of Figure 7A is then formed into a flap preform (70) illustrated in Figure 7B and comprising spaced layers (71) in the area (6) and a flap (5) rolled, wound or folded , along the edge parts, in an operation identical to that illustrated in FIG. 5 above. The flap preform (70) resulting from FIG. 7B can be

  substantially flat or of another desired shape.

  The major advantage of the flap preform (70) of Figure 7B is that the flap preform can be stored and / or transported, using minimal space or volume, more efficiently than the entire final three-dimensional part studied. . The flap preform (70) of FIG. 7B is then formed in a final stamping operation in the final studied part (1) illustrated in FIG. 7C and comprising a spaced zone (6), compressed corner zones or stretched (2), a folded area (4) formed of folds, folds or ribs (8) and a flap area (5). The forming of intermediate preforms, flap preforms, or partially shaped preforms can be divided into as many forming steps as desired, but the best performance of the present invention will be achieved with the fewest steps separate forming operations as possible consistent with the requirements of a manufacturing industry and

particular assembly.

  It will be evident from the presentation below

  above that many variations and modifications of the methods of the present invention for forming multilayer metal sheet preforms to form structural multilayer metal sheet screens, as well as many models and configurations of the resulting multilayer metal sheet screens resulting from the present invention, can be applied by a specialist in the art without departing from the spirit and the field of the present invention. In this regard, it will be assumed that the selection of materials for the layers of metal foil, the selection of the thicknesses of the various layers, the selection of the number of layers of metallic foils, the selection of methods and configurations for making the spaces between the layers in the desired area, the selection of the extent to which the various parts of the screens

  are stretched by traction or reciprocally compressed or locked

  The selection of materials, if any, to be placed between the layers of metal foil, etc., are all included in the skills of a person following the teachings of

  the present invention. For example, metal foil screens-

  multilayer liquor according to the present invention can contain from three to as many layers as appropriate as required

  thermal or acoustic protection for an application par-

  particular, taking into account the economic side of the screen product. Typically, however, five to nine layers of metallic foil are suitable for application purposes. Likewise, the thicknesses of the different sizes of the metallic sheet vary from 0.02032 mm (0.0008 inch) to 0.01524 m (0.0006 inch), the metallic shells from 0.0508 mm (0.002 inch) and 0.127 min (0.005 inch) spread preferable for many applications. The top layers or protective layers used in conjunction with the metal sheets may have any desired thickness which is adaptable to the forming and forming process.

  forming to manufacture the screens according to the present invention.

  It is preferable that the top layers or the outer protective layers usually have a thickness of 0.254 mm (0.010 inch) up to about 1.27 mm (0.050 inch) for most normal screen applications. Some typical examples of layers used in the formed multi-layer metallic foil screens of the present invention are: in millimeters (in thousandths of an inch, 1 thousandths of an inch = 0.001 inches) 0.254 / 0.0508 / 0.0508 / 0.0508 / 0, 127 min (10/2/2/2/5 pce); 0.127 / 0.0508 / 0.0508 / 0.0508 / 0.0508 / 0.127 mm (5/2/2/2/2/5 inch); 0.2032 / 0.0508 / 0.0508 / 06508 / 0.1016 / 0.1016 / 0.2032 min (8/2/2/2/4/4/8 hen); 0.762 / 0.1016 / 0.1016 / 0.0508 / 0.0508 / 0.127 min (30/4/4/2/2/5 microchip); 0.254 / 0.0508 / 0.0508 / 0.254 min (10/2/2/10 peacemaking); 0.127 / 0.0508 / 0.0508 min (5/2/2 p _e); 0.254 / 0.0508 / 0.127 min (10/2/5 inchi) and 0.254 / 0.0508 / 0.02032 / q02032 / 0.127 min (10/2 / 0.8 / 0.8 / 5 inch). EXAMPLES OF STARS IN FAll DILE E FAIE ÎTétalliql -2t: 0, 254 / 0.2032 / 0.232 / 0.2032

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  mm (10/8/8/8 puoe); 0.762 / 0.254 / 0.254 / 0.254 / 0.762 mm (30/10/10/10/30 pcuoe); 0.2032 / 0.2032 / 0.2032 nm (8/8/8 E) and 1.27 / 0.2032 / 0.2032 / 0.254 min (50/8/8/10 hen). The materials useful in the present invention are more commonly aluminum and stainless steel, but other useful materials will be obvious to those skilled in the art, including: copper, tin, galvanized sheet, brass , etc. An expert in the art can easily select suitable combinations of materials and thicknesses of metal sheets and sheet metal for specific use applications, for forming processes and configurations.

  specific molds and for the particular metals used.

  The total thickness of the screen or the part will depend not only on the number of layers, the thickness of the layers and the spaces between the layers, but also on the possibility of shaping and the formability of the preform. or the flap preform in order to produce the desired final shaped and studied part. The thickness will vary between 0.254 mm (0.010

  inch) and 6.35 mm (0.25 inch) or more.

  It will also be obvious to a specialist in the art according to the above presentation, that screens or parts can be produced according to the present invention without using metallic sheets, that is to say using sheets

  sheet metal thickness greater than 0.1524 mm (0.006 inch).

  Examples of these structures would include 0.254 / 0.1775 / 0.254 mm (10/7/10 inch); 0.508 / 0.254 / 0.254 / 0.254 mm (20/10/10/10 inch; 0.762 / 0, 2032 / 0.2032 / 0.2032 mm (30/8/8/8 inch) and the like, where layers are selected in order to carry out a suitable forming and shaping using the methods presented here for the preforms in multilayer sheet metal sheet.

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  Although the present invention has been described and illustrated in terms of thermal and acoustic screens, it will be evident that the sheet metal and multi-layer metallic sheet structures of the present invention and the methods of the present invention will have many other uses. also, such as devices for preparing and serving food.

Claims (25)

  1. A multilayered metal sheet structure formed characterized in that it comprises: a stack of at least three layers of sheet metal sheet, in which at least two of the layers are metal sheets with a thickness of 0.006 inch (0, 15 mm) or less, and at least a portion of the layers are spaced apart by spaces between the layers, and said stack being formed three-dimensionally from a preform of a stack of layers of spaced metal foil layers, in such a manner that part of the metal foil layers is stretched to form an angle in the three-dimensional structure and part of the metal foil layers is compressed to lock the metal foil layers with each other to form a structure unitary multilayer, so that there are, in a part of the three-dimensional structure formed, spaces   between the layers of metal foil.   2. Multilayer metal sheet structure formed according to claim 1, characterized in that the layers are locked with each other in folds, rolls, folds, reels, flaps or in windings.   3. Multilayer metal sheet structure formed according to claim 1, characterized in that the preform comprises a stack of embossed metal sheets and, in the stretched part of the layers, the   bosses (7) are significantly reduced.   4. Multilayer metal sheet structure formed according to claim 2, characterized in that the layers are locked with each other in a cylindrical roller of the layers at a edge of the structure.   5. A multilayer metal sheet structure formed according to claim 1, characterized in that the compressed part for interlocking the layers comprises a wall section (4) in which the layers are folded and locked with each other and a section of rolled edge in which the layers are locked together   the others in a cylindrical edge roller (5).   6. Method for forming a multilayer metal sheet structure, characterized in that it comprises: providing a multilayer preform of a stack of spaced layers of metal sheet, comprising at least three layers of sheet metal, two layers of which at least are metal sheets having a thickness of 0.15 mm (0.006 inch) or less; and forming said stack of multilayer preform into a three-dimensional shape on a mold, so that, in a first part of the preform, the layers are subjected to a tensile stress to stretch and shape this part of the stack of preform in order to form an angle in the desired three-dimensional shape and that, in a second part of the preform, the layers are subjected to compression in order to put part of the preform in a three-dimensional shape in order to give structural resistance to the metallic structure by locking the layers together, to form a sheet structure SR 15592 US / JB   unitary metallic multi-layer, so that there are, in a part of the three-dimensional structure formed, spaces between the layers of metallic foil.   7. Method for forming a multilayer metal sheet structure according to claim 6, characterized in that the locking of the layers is carried out by forming the layers in folds, in rolls,   in folds, in reels, in flaps or in windings.   8. Method for forming a multilayer metal sheet structure according to claim 6, characterized in that the preform is provided as a stack of layers of metal sheet which are bumpy, corrugated or folded in order to produce spaces between layers.   9. Method for forming a multilayer metal sheet structure according to claim 7, characterized in that the metal sheet layers are locked with each other in a cylindrical roller of the layers at an edge of the structure.   10. Method for forming a multilayer metal sheet structure according to claim 8, characterized in that the stretching of a part of the preform to form an angle substantially reduces the bosses (7), the undulations or the folds in this part of the structure.   11. Method for forming a multilayer metal sheet structure according to claim 6, characterized in that the preform is partially shaped in a forming step, the final structure then being formed in a second forming step. 12. The method of claim 11, characterized in that the partially shaped preform is formed with the metal layers folded, wound, folded, wound, crimped or rolled at the edge portions to form a flap preform. 13. Method for forming a multilayer metal sheet structure according to claim 6, characterized in that the preform is formed into the final structure in a forming step or single stamping.   14. Multilayer metal sheet structure characterized in that it comprises: at least three layers of sheet metal sheet, of which at least two of the layers are metal sheets with a thickness of 0.15 mm (0.006 inch) or less formed in a unitary structure, in such a way that, in a part of the structure, spaces are made between the layers by spacers which keep the layers spaced apart in order to make said spaces and that, in a part of the structure, the layers are compressed and locked with each other to eliminate gaps between the layers, wherein said multilayer structure comprises: a base portion in which there are gaps between the metal layers; a wall portion positioned contiguous with the base portion and at an angle to the plane thereof, in which the metal layers are folded or folded; a corner portion positioned between the base portion and the wall portion where the metal layers are stretched or stretched to form said SR 15592 US / JB   overlap between the plane of the base part and the plane of the wall part; and an edge portion contiguous with the base portion or the wall portion, in which the layers are locked with each other. 15. A multilayer metal sheet structure according to claim 14, characterized in that it   includes at least four layers of metal foil.   16. Vehicle on a bodywork or chassis part of which a thermal or acoustic screen (1) is positioned, characterized in that the screen (1) comprises a multilayer metallic structure formed by forging, comprising: a stack of at least three layers of sheet metal sheet, in which at least two of the layers are metal sheets with a thickness of 0.006 inch (0.15 mm) or less, and at least a portion of the layers are spaced apart by spaces between the layers, and said stack being formed three-dimensionally from a preform of a stack of spaced layers of metal foil, such that a portion of the layers of metal foil is stretched to form an angle in the three-dimensional structure and qu a part of the metal foil layers is compressed in order to lock the metal foil layers with each other in order to form a unitary multilayer structure, in such a way e that there are, in a part of the three-dimensional structure formed, spaces   between the layers of metal foil.   17. Multilayer sheet metal sheet structure formed, characterized in that it comprises: a stack of at least three layers of sheet metal, in which the layers are sheet metal with a thickness greater than 0.15 mm ( 0.006 inch) and at least a portion of the layers are spaced apart by spaces between the layers, and said stack being formed three-dimensionally from a preform of a stack of spaced metallic layers, such that a portion of metal layers is stretched to form an angle in the three-dimensional structure and a part of the metal layers is compressed in order to lock the metal layers with each other in order to form a unitary multilayer structure, so that there is , in part of the three-dimensional structure   formed, spaces between the metal layers.   18. Multilayer sheet metal sheet structure formed according to claim 17, characterized in that the layers are locked with one another in the edge part in folds, in rolls, in folds, in   spools, in flaps or in windings.   19. Preform structure with a flap made of a multilayer metal sheet formed, characterized in that it comprises: a stack of at least three layers of sheet metal sheet, in which at least two of the layers are metal sheets with a thickness of 0 , 15 mmn (0.006 inch) or less, and at least a portion of the layers are spaced apart by spaces between the layers, and said stack being formed three-dimensionally from a preform of a stack of spaced layers of metal foil , so that part of the metal foil layers SR 15592 US / JB   is compressed and a flap is formed at the edge portion in order to lock the layers of metal foil with each other in pleats, rolls, folds, coils, flaps or coils to form a unitary multilayer structure, such that, in a part of the flap preform structure (70), there are   spaces between layers of metal foil.   20. A method for forming a multilayer sheet sheet structure characterized in that it comprises: providing a multilayer preform of a stack of at least three layers of sheet sheets each having a thickness greater than 0.15 mm (0.006 inch); and forming said stack of multilayer preform into a three-dimensional shape on a mold, so that, in a first part of the preform, the layers are subjected to a tensile stress to stretch and shape this part of the stack of preform in order to form an angle in the desired three-dimensional shape and that, in a second part of the preform, the layers are subjected to compression in order to put part of the preform in a three-dimensional shape in order to give structural resistance to the metallic structure by interlocking the layers with each other, to form a unitary sheet metal sheet structure, so that there is, in a part of the three-dimensional structure   formed, spaces between the metal layers.   21. Method for forming a multilayer sheet sheet structure according to claim 20, characterized in that the interlocking of the layers at the SR 15592 US / JB   level of the edge part is done by forming the layers in folds, in rolls, in folds, in coils, in flaps or coils.   22. Method for forming a multilayer sheet sheet structure according to claim 21, characterized in that the preform is partially shaped in a forming step and the final structure is   then formed in a second forming step.   23. The method of claim 22, characterized in that the partially shaped preform is formed with the metal layers folded, wound, folded, wound, crimped or rolled at the edge portions to form a flap preform (70 ). 24. Multilayer sheet metal structure characterized in that it comprises: at least three layers of sheet metal each having a thickness greater than 0.006 inch (0.15 mm) formed into a unitary structure, so that it there are, in a part of the structure, spaces between the layers produced by spacers which keep the layers separated in order to make said spaces and that, in a part of the structure, the layers are compressed and locked together with the others in order to eliminate the spaces between the layers, in which said multilayer structure comprises: a base part in which there are spaces between the metal layers; a wall portion positioned adjacent to and at an angle to the plane of the base portion, in which the metal layers are folded or folded; a corner portion positioned between the base portion and the wall portion, where the metal layers are stretched or stretched to form said overlap between the plane of the base portion and the plane of the wall portion; and an edge portion contiguous to the base portion or the wall portion, in which the layers are   locked with each other.   25. A multilayer sheet sheet structure according to claim 24 characterized in that it comprises   at least four layers of sheet metal.